Notices
Explorer, Sport Trac, Mountaineer & Aviator 1991-1994, 1995-2001, 2002-2005, 2006-2010 Ford Explorer

URGENT HELP

Thread Tools
 
Search this Thread
 
Old Jan 23, 2014 | 05:35 AM
  #1  
slaterkey's Avatar
slaterkey
Thread Starter
|
New User
Joined: Jan 2014
Posts: 8
Likes: 0
URGENT HELP

HI, i've got a 97 explorer xlt 5speed.... here is the problem...

when you start the truck and start driving... its making a Loud clunking noise from under the car... at first we thought it was the gear box but then after replacing with a reconditioned gearbox and transfer case it was still there... it is doing this in auto mode and in 4x4 mode... during city driving it does it all the time .... but when you drive it to 100km/h the clunking completely stops.... and then you can bring the car to a complete halt (without turning the engine off) and start driving again and the clunking is still gone... BUT as soon as you turn the engine off and on again (even if only for a minute) the clunking returns again until you drive to 100km/h and then it stops again.

HELP PLEASE
 
Reply
Old Jan 23, 2014 | 05:38 AM
  #2  
kanuck15's Avatar
kanuck15
Junior User
Joined: Jan 2014
Posts: 55
Likes: 0
Look over all the universals. Can you feel the clunk or is it just a noise?
 
Reply
Old Jan 23, 2014 | 05:47 AM
  #3  
slaterkey's Avatar
slaterkey
Thread Starter
|
New User
Joined: Jan 2014
Posts: 8
Likes: 0
nah the clunking can be felt.

but i'm just confused as to why it would stop when it gets to 100kmh and stay good until the truck is turned off.
 
Reply
Old Jan 23, 2014 | 05:48 AM
  #4  
slaterkey's Avatar
slaterkey
Thread Starter
|
New User
Joined: Jan 2014
Posts: 8
Likes: 0
also what is the solenoid looking thing attached to the transfer case?
 
Reply
Old Jan 23, 2014 | 06:12 AM
  #5  
kanuck15's Avatar
kanuck15
Junior User
Joined: Jan 2014
Posts: 55
Likes: 0
Im going to assume you are talking about the transfer case shift motor?
 
Reply
Old Jan 23, 2014 | 06:30 AM
  #6  
slaterkey's Avatar
slaterkey
Thread Starter
|
New User
Joined: Jan 2014
Posts: 8
Likes: 0
well that shift motor isn't all the way in... the three screws that hold the casing on are missing and theres about a 5mm gap... it its only being held on by the bracket that is holding the end of the casing. i've tried removing it completely to see if it makes any difference... but none.
 
Reply
Old Jan 23, 2014 | 06:37 AM
  #7  
kanuck15's Avatar
kanuck15
Junior User
Joined: Jan 2014
Posts: 55
Likes: 0
That doesnt seem right? I wonder if your transfer case isnt going nuts inside
 
Reply
Old Jan 23, 2014 | 07:16 PM
  #8  
Ford_Six's Avatar
Ford_Six
Hotshot
Joined: Oct 2002
Posts: 18,488
Likes: 22
From: The Big, Oregon
Club FTE Gold Member
You will probably get more coverage in the Explorer forum, I'll move this up there for you.
 
Reply
FTE Stories

Ford Trucks for Ford Truck Enthusiasts

story-0

Top 10 Ford Truck Tragedies

 Joe Kucinski
story-1

AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make

 Brett Foote
story-2

Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!

 Michael S. Palmer
story-3

Ford's 2001 Explorer Sportsman Concept Looks For a New Home

 Verdad Gallardo
story-4

10 Best Ford Truck Engines We Miss the Most!

 Joe Kucinski
story-5

2026 Shelby F-150 Off-Road: Better Than a Raptor R?

 Brett Foote
story-6

2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!

 Michael S. Palmer
story-7

10 Most Surprising 2026 Ford Truck Features!

 Joe Kucinski
story-8

Top 10 Ford Trucks Coming to Mecum Indy 2026

 Brett Foote
story-9

5 Best / 5 Worst Ford Truck Wheels of All Time

 Joe Kucinski
Old Jan 23, 2014 | 09:28 PM
  #9  
shorod's Avatar
shorod
Logistics Pro
15 Year Member
Photogenic
Liked
Loved
Joined: Jun 2009
Posts: 4,808
Likes: 83
From: Cedar Rapids, IA
Do you still have the original transfer case? If so, can you use the screws from the old case to hold the shift motor in? Did the new transmission and transfer case may any improvement?

I'll also suggest you drain the front and rear differential fluids and see if there is any sign that the gears are not meshed correctly or have other issues (fluid will have a grey sparkly tint to it).

Is the noise only present when the vehicle is moving with no hints of the noise parked at idle? Are you pretty sure the noise isn't parking brake shoes that have come free from the backing plates? I'm not totally sure this would create a noise that goes away at high speed and doesn't come back until the vehicle has sat some amount of time.

-Rod
 
Reply
Old Jan 23, 2014 | 11:19 PM
  #10  
weross67's Avatar
weross67
Senior User
Joined: Oct 2013
Posts: 145
Likes: 0
From: South Mississippi
Arrow

I have repaired this problem several times in most situations it is the rear differential the noise comes up the drive shaft and sounds like the transmission.
It can also be the front differential there is generally a small leak on the input shaft in either case.
You should also address the transfer case problem also.
 
Reply
Old Jan 24, 2014 | 02:00 AM
  #11  
slaterkey's Avatar
slaterkey
Thread Starter
|
New User
Joined: Jan 2014
Posts: 8
Likes: 0
only sounds while driving... and when you turn the truck off and STRAIGHT on again the sound returns.
 
Reply
Old Jan 24, 2014 | 06:39 AM
  #12  
shorod's Avatar
shorod
Logistics Pro
15 Year Member
Photogenic
Liked
Loved
Joined: Jun 2009
Posts: 4,808
Likes: 83
From: Cedar Rapids, IA
The cheap and relatively easy check might still be to pull the rear brake rotors and see if there is brake shoe lining material floating around. And if there is it still may not be the source of this noise, but would be probably the cheapest thing to try and yet not be a waste of time.

-Rod
 
Reply
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
1989bricknose
1987 - 1996 F150 & Larger F-Series Trucks
13
May 19, 2016 10:32 AM
slaterkey
Explorer, Sport Trac, Mountaineer & Aviator
2
Jan 25, 2014 09:12 AM
Cannon45
Explorer, Sport Trac, Mountaineer & Aviator
5
Dec 3, 2012 01:04 PM
bbslamjam
Explorer, Sport Trac, Mountaineer & Aviator
3
Oct 21, 2011 11:56 PM
Pwnm30rdi3
1980 - 1986 Bullnose F100, F150 & Larger F-Series Trucks
6
Nov 29, 2010 06:15 AM




All times are GMT -5. The time now is 04:26 AM.

story-0
Top 10 Ford Truck Tragedies

Slideshow: Top 10 Ford truck tragedies.

By Joe Kucinski | 2026-05-18 19:34:33


VIEW MORE
story-1
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make

And it might be even better than that.

By Brett Foote | 2026-05-18 19:26:42


VIEW MORE
story-2
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!

Slideshow: Does lowering an F-150 Lobo RUIN the ride quality?

By Michael S. Palmer | 2026-05-18 19:20:37


VIEW MORE
story-3
Ford's 2001 Explorer Sportsman Concept Looks For a New Home

Slideshow: Ford's bizarre fishing-themed Explorer concept has resurfaced after spending decades largely forgotten.

By Verdad Gallardo | 2026-05-12 18:07:46


VIEW MORE
story-4
10 Best Ford Truck Engines We Miss the Most!

Slideshow: The 10 best Ford truck engines we miss the most.

By Joe Kucinski | 2026-05-12 13:09:47


VIEW MORE
story-5
2026 Shelby F-150 Off-Road: Better Than a Raptor R?

Slideshow: first look at the 810 hp 2026 Shelby F-150 Off-Road!

By Brett Foote | 2026-05-12 12:50:07


VIEW MORE
story-6
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!

Slideshow: Everything You Need to Know about the 2027 Super Duty Carhartt Package!

By Michael S. Palmer | 2026-05-07 17:51:06


VIEW MORE
story-7
10 Most Surprising 2026 Ford Truck Features!

Slideshow: 10 most surprising Ford truck options/features in 2026.

By Joe Kucinski | 2026-05-05 11:17:22


VIEW MORE
story-8
Top 10 Ford Trucks Coming to Mecum Indy 2026

Slideshow: Here are the top 10 Fords coming to Mecum Indy 2026.

By Brett Foote | 2026-05-04 13:49:49


VIEW MORE
story-9
5 Best / 5 Worst Ford Truck Wheels of All Time

Slideshow: The 5 best and 5 worst Ford truck wheels of all time

By Joe Kucinski | 2026-04-29 16:49:01


VIEW MORE